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United States Patent |
6,087,639
|
Engelke
,   et al.
|
July 11, 2000
|
Heating coil retainer bracket and method for manufacturing the same
Abstract
A retainer bracket for an electric heating assembly is provided with a pair
of parallel and opposing side beams having longitudinal axes and at least
one planar transverse support formed integral with the pair of side beams
and extending between the pair of side beams. The transverse support
preferably has a plurality of openings with longitudinal axes and the
transverse support is disposed so that the axes of the openings are
parallel to the longitudinal axes of the side beams. The plurality of
openings are thereby each adapted to receive and retain an insulator
without a separate fastener. A method of making the heating coil retainer
bracket from a single web of material is also contemplated.
Inventors:
|
Engelke; Roger P. (Holland, MI);
Lietch; Leon (Huntsville, AL)
|
Assignee:
|
Hart & Cooley, Inc. (Holland, MI)
|
Appl. No.:
|
350617 |
Filed:
|
July 9, 1999 |
Current U.S. Class: |
219/542; 29/611; 174/148; 219/532 |
Intern'l Class: |
H05B 003/06 |
Field of Search: |
174/138 S,148
219/532,542
392/350
29/611
|
References Cited
U.S. Patent Documents
1628876 | May., 1927 | Ehrgott.
| |
3641312 | Feb., 1972 | Ammerman et al. | 219/532.
|
3697727 | Oct., 1972 | Neuman et al. | 219/532.
|
3811031 | May., 1974 | McBride et al. | 392/350.
|
3812322 | May., 1974 | Osterkorn et al. | 219/532.
|
3883721 | May., 1975 | Paulson et al. | 219/532.
|
3890487 | Jun., 1975 | Wightman et al.
| |
3920887 | Nov., 1975 | Kloos et al. | 174/148.
|
3943333 | Mar., 1976 | Kokjohn et al. | 219/532.
|
3952409 | Apr., 1976 | Allison et al.
| |
3963859 | Jun., 1976 | Peterson et al. | 174/148.
|
3992609 | Nov., 1976 | Alexander.
| |
4628189 | Dec., 1986 | Danko | 219/532.
|
4656340 | Apr., 1987 | St. Louis.
| |
5122640 | Jun., 1992 | Holmes | 219/532.
|
5134270 | Jul., 1992 | Bragg et al. | 219/532.
|
5477605 | Dec., 1995 | McWilliams et al. | 29/611.
|
Primary Examiner: Walberg; Teresa
Assistant Examiner: Fastovsky; Leonid
Attorney, Agent or Firm: Rader, Fishman, Grauer & McGarry
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application
Ser. No. 60/093,199 filed on Jul. 17, 1998.
Claims
What is claimed is:
1. A retainer bracket blank for an electric heating assembly comprising:
a pair of parallel and opposing side beams having longitudinal axes;
at least one planar transverse support extending between the pair of side
beams, the transverse support and the side beams formed as an integral
unit into a planar member;
said transverse support having a plurality of openings with longitudinal
axes;
said transverse support being movable into a plane other than the plane of
the planar member so that the axes of the openings can be parallel to the
longitudinal axes of the side beams;
whereby a retainer bracket can be formed from the retainer bracket blank
and can retain insulators without any separate fasteners or connections.
2. The retainer bracket blank of claim 1 wherein the side beams are
L-shaped for reinforcement thereof.
3. The retainer bracket blank of claim 2 and further comprising a plurality
of locking tabs extending into each of said openings adapted to retain
insulators therein.
4. The retainer bracket blank of claim 3 wherein the insulators are mounted
within each of the openings.
5. The retainer bracket blank of claim 4 and further comprising locking
tabs bent located within each of the openings wherein the insulators are
retained within the openings by the locking tabs.
6. The retainer bracket blank of claim 5 wherein the locking tabs are each
bent in at least one of a first lateral direction and a second lateral
direction whereby the locking tabs prevent movement of the insulators
within the openings in the at least the first and second directions.
7. The retainer bracket blank of claim 6 wherein the at least one
transverse support comprises at least two transverse supports wherein the
plurality of openings on one transverse support are aligned with the
plurality of openings on another transverse support.
8. The retainer bracket blank of claim 7 and further comprising a heater
coil wound in serpentine fashion through the plurality of openings in each
transverse support.
9. The retainer bracket blank of claim 1 wherein the at least one
transverse support is a single planar member.
10. The retainer bracket blank of claim 1 and further comprising a support
flange formed integrally with each end of the at least one transverse
support and extending between the end of the at least one transverse
support and the adjacent side beam;
wherein each support flange is twisted so that the axis of each of the
plurality of openings is parallel to the longitudinal axes of the opposing
side beams.
11. The retainer bracket blank of claim 10 wherein at least one of the
openings on the at least one transverse support comprises a circular
aperture therein.
12. The retainer bracket blank of claim 10 wherein the transverse support
has a first transverse edge and at least one of the openings on the at
least one transverse support comprises a partial circular aperture
extending inwardly from the transverse edge.
13. The retainer bracket blank of claim 1 and further comprising a
plurality of locking tabs extending into each of said openings adapted to
retain insulators therein.
14. The retainer bracket blank of claim 1 and further comprising a
plurality of insulators, each mounted within a corresponding one of the
plurality of openings in the at least one transverse support.
15. The retainer bracket blank of claim 1 and further comprising locking
tabs located within each of the plurality of openings.
16. The retainer bracket blank of claim 15 wherein the locking tabs are
each bent in at least one of a first lateral direction and a second
lateral direction whereby the locking tabs prevent movement of an
insulator located within the openings in the at least the first and second
lateral directions.
17. The retainer bracket blank of claim 1 wherein the at least one
transverse support comprises at least two transverse supports wherein the
plurality of openings on one transverse support are aligned with the
plurality of openings on another transverse support.
18. The retainer bracket blank of claim 17 and further comprising a heater
coil wound in serpentine fashion through the plurality of openings in each
transverse support.
19. A retainer bracket for an electric heating assembly comprising:
a pair of parallel and opposing side beams having longitudinal axes;
at least one planar transverse support extending between the pair of side
beams, the transverse support and the side beams formed as an integral
unit into a planar member;
said transverse support having a plurality of openings with longitudinal
axes; and
wherein the at least one transverse support is moved so that the axis of
each of the plurality of openings is parallel to the longitudinal axes of
the opposing side beams.
20. The retainer bracket of claim 19 wherein the side beams are L-shaped
for reinforcement thereof.
21. The retainer bracket of claim 20 and further comprising a plurality of
locking tabs extending into each of said openings adapted to retain
insulators therein.
22. The retainer bracket of claim 21 wherein the insulators are mounted
within each of the openings.
23. The retainer bracket of claim 22 and further comprising locking tabs
bent located within each of the openings wherein the insulators are
retained within the openings by the locking tabs.
24. The retainer bracket of claim 23 wherein the locking tabs are each bent
in at least one of a first lateral direction and a second lateral
direction whereby the locking tabs prevent movement of the insulators
within the openings in the at least the first and second directions.
25. The retainer bracket of claim 24 wherein the at least one transverse
support comprises at least two transverse supports wherein the plurality
of openings on one transverse support are aligned with the plurality of
openings on another transverse support.
26. The retainer bracket of claim 25 and further comprising a heater coil
wound in serpentine fashion through the plurality of openings in each
transverse support.
27. The retainer bracket of claim 19 wherein at least one of the openings
on the at least one transverse support comprises a circular aperture
therein.
28. The retainer bracket of claim 19 wherein the transverse support has a
first transverse edge and at least one of the openings on the at least one
transverse support comprises a partial circular aperture extending
inwardly from the transverse edge.
29. The retainer bracket of claim 19 and further comprising a plurality of
locking tabs extending into each of said openings adapted to retain
insulators therein.
30. The retainer bracket of claim 19 and further comprising a plurality of
insulators, each mounted within a corresponding one of the plurality of
openings in the at least one transverse support.
31. The retainer bracket of claim 19 and further comprising locking tabs
located within each of the plurality of openings.
32. The retainer bracket of claim 31 wherein the locking tabs are each bent
in at least one of a first lateral direction and a second lateral
direction whereby the locking tabs prevent movement of an insulator
located within the openings in the at least the first and second lateral
directions.
33. The retainer bracket of claim 19 wherein the at least one transverse
support comprises at least two transverse supports wherein the plurality
of openings on one transverse support are aligned with the plurality of
openings on another transverse support.
34. The retainer bracket of claim 33 and further comprising a heater coil
wound in serpentine fashion through the plurality of openings in each
transverse support.
35. In an electric heating assembly comprising a heating element supported
by a plurality of insulators mounted to a retainer bracket, the retainer
bracket comprising a pair of a pair of parallel and opposing side beams
having longitudinal axes, at least one transverse support formed with the
pair of side beams and extending between the pair of side beams, said
transverse support having a plurality of openings with longitudinal axes,
wherein the plurality of openings are each adapted to receive and retain
an insulator without a separate fastener, the improvement comprising:
the opposing side beams and the at least one planar transverse support
being formed as an integral unit into a planar member, the at least one
transverse support being deformed relative to the opposing side beams so
that the at least one transverse support is oriented in a plane other than
the plane of the planar member so that the axes of the openings are
parallel to the longitudinal axes of the side beams.
36. The electric heating assembly of claim 35 wherein at least one of the
openings on the at least one transverse support comprises a circular
aperture therein.
37. The electric heating assembly of claim 35 wherein the transverse
support has a first transverse edge and at least one of the openings on
the at least one transverse support comprises a partial circular aperture
extending inwardly from the transverse edge.
38. The electric heating assembly of claim 35 and further comprising a
plurality of locking tabs extending into each of said openings adapted to
retain insulators therein.
39. The electric heating assembly of claim 35 and further comprising a
plurality of insulators, each mounted within a corresponding one of the
plurality of openings in the at least one transverse support.
40. The electric heating assembly of claim 35 and further comprising
locking tabs located within each of the plurality of openings.
41. The electric heating assembly of claim 40 wherein the locking tabs are
each bent in at least one of a first lateral direction and a second
lateral direction whereby the locking tabs prevent movement of an
insulator located within the openings in the at least the first and second
lateral directions.
42. The electric heating assembly of claim 35 wherein the at least one
transverse support comprises at least two transverse supports wherein the
plurality of openings on one transverse support are aligned with the
plurality of openings on another transverse support.
43. The electric heating assembly of claim 42 and further comprising a
heater coil wound in serpentine fashion through the plurality of openings
in each transverse support.
44. In an electric heating assembly comprising a heating element supported
by a plurality of insulators mounted to a retainer bracket, the retainer
bracket comprising a pair of a pair of parallel and opposing side beams
having longitudinal axes, at least one transverse support formed with the
pair of side beams and extending between the pair of side beams, said
transverse support having a plurality of openings with longitudinal axes,
said transverse support disposed so that the axes of the openings are
parallel to the longitudinal axes of the side beams, the improvement
wherein:
the opposing side beams and the at least one transverse support are formed
from a unitary planar length of material.
45. The electric heating assembly of claim 44 wherein at least one of the
openings on the at least one transverse support comprises a circular
aperture therein.
46. The electric heating assembly of claim 44 wherein the transverse
support has a first transverse edge and at least one of the openings on
the at least one transverse support comprises a partial circular aperture
extending inwardly from the transverse edge.
47. The electric heating assembly of claim 44 and further comprising a
plurality of locking tabs extending into each of said openings adapted to
retain insulators therein.
48. The electric heating assembly of claim 44 and further comprising a
plurality of insulators, each mounted within a corresponding one of the
plurality of openings in the at least one transverse support.
49. The electric heating assembly of claim 44 and further comprising
locking tabs located within each of the plurality of openings.
50. The electric heating assembly of claim 49 wherein the locking tabs are
each bent in at least one of a first lateral direction and a second
lateral direction whereby the locking tabs prevent movement of an
insulator located within the openings in the at least the first and second
lateral directions.
51. The electric heating assembly of claim 44 wherein the at least one
transverse support comprises at least two transverse supports wherein the
plurality of openings on one transverse support are aligned with the
plurality of openings on another transverse support.
52. The electric heating assembly of claim 51 and further comprising a
heater coil wound in serpentine fashion through the plurality of openings
in each transverse support.
53. A method of forming a heating coil retainer bracket for an electric
heating assembly by advancing a piece of sheet metal through a plurality
of workstations comprising the steps of:
removing excess material from the piece of sheet metal to form a pair of
parallel and opposing side beams having longitudinal axes, at least one
planar transverse support extending between, and formed unitary with, the
pair of side beams, and a plurality of openings with longitudinal axes in
the at least one transverse support;
bending the at least one transverse support wherein the axes of the
openings are parallel to the longitudinal axes of the side beams; and
mounting an insulator within each of the plurality of openings.
54. The method of claim 53 and further comprising the step of bending the
side beams into a channel beam.
55. The method of claim 54 and further comprising the step of forming
retainer tabs on the openings.
56. The method of claim 55 and further comprising the step of forming
support flanges on the ends of the transverse support.
57. The method of claim 56 and further comprising the step of twisting the
support flanges during the step of bending the at least one transverse
support.
58. A heater coil retainer bracket formed by the method of claim 53.
59. The method of claim 53 and further comprising the step of forming
retainer tabs on the openings.
60. The method of claim 53 and further comprising the step of forming
support flanges on the ends of the transverse support.
61. The method of claim 53 and further comprising the step of twisting the
support flanges during the step of bending the at least one transverse
support.
62. A method of forming an electric heating assembly comprising the steps
of:
removing excess material from a piece of sheet metal to form a pair of
parallel and opposing side beams having longitudinal axes, at least one
planar transverse support extending between, and formed unitary with, the
pair of side beams, and a plurality of openings with longitudinal axes in
the at least one transverse support;
bending the at least one transverse support wherein the axes of the
openings are parallel to the longitudinal axes of the side beams;
mounting an insulator within each of the plurality of openings; and
winding a heating coil in serpentine fashion through longitudinal bores in
the insulators.
63. An electric heating assembly formed by the method of claim 62.
64. The retainer bracket of claim 19 wherein a support flange extends
between the at least one transverse support and the adjacent side beam.
65. The retainer bracket of claim 64 wherein the support flange has a
twisted portion to accommodate the movement of the transverse support
relative to the side beam.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a heater assembly and in particular to a retainer
bracket for mounting a heating coil of the heater assembly and to a method
for manufacturing the retainer bracket.
2. Related Art
Heating assemblies having coil-type heating elements are generally formed
by passing the coil element, usually in a serpentine manner, through ring
or grommet-type insulators which are supported by a metal retainer
bracket. The object of the manufacture of these retainer brackets is to
provide a rigid, and therefore reliable, retainer bracket at the lowest
cost in materials, labor, and tooling.
A common method of producing the retainer bracket is to advance a piece of
sheet metal through a plurality of work stations, such as in a progressive
die machine, whereby particular features of the retainer bracket are
formed at each station. Typically, once the sheet metal is deformed
through stamping, side supports are connected by rivets or screws to the
stamped structure for the purpose of increasing rigidity of the completed
retainer bracket. Using fasteners to secure the side supports increases
the overall material costs in assembling the retainer bracket and
increases the cost of manufacture thereof.
It is paramount to the integrity of the assembly of the retainer bracket
that the particular structure that receives and retains the heating coils
be rigidly attached to the retainer bracket. More specifically, when that
particular structure is not integral to the support structure, overall
rigidity and reliability of the retainer bracket is lessened and the costs
of manufacture are increased.
For example, U.S. Pat. No. 3,952,409 to Allison et al. teaches a bracket
for an electric heating assembly comprising a pair of parallel side
supports which mount several separate U-shaped transverse supports
interlocked with the side supports by a tab-in-slot arrangement. The
U-shaped supports have a pair of spaced side walls which form a recess for
receipt of several insulator blocks which are held in place by tabs bent
over a tab on each of the insulator blocks.
U.S. Pat. No. 3,992,609 to Alexander discloses a bracket very similar to
that shown in the Alexander '609 patent but wherein the U-shaped supports
for the insulator blocks are formed integral with the side supports. A
planar, undeformed connecting piece of material extends between the side
supports and the U-shaped supports to provide support between the
respective components of the bracket.
However, these and other prior art attempts still require additional
manufacturing cost as well as require additional material and fasteners
for assembly of the heating coil retainer bracket with sufficient
structural strength.
SUMMARY OF THE INVENTION
In one aspect, the invention relates to a retainer bracket for an electric
heating assembly comprising a pair of parallel and opposing side beams
having longitudinal axes, at least one planar transverse support formed
integral with the pair of side beams and extending between the pair of
side beams, the transverse support having a plurality of openings with
longitudinal axes, and the transverse support disposed so that the axes of
the openings are parallel to the longitudinal axes of the side beams. The
plurality of openings are thereby each adapted to receive and retain an
insulator without a separate fastener.
In various embodiments of the aspects of the invention, the side beams can
be L-shaped for reinforcement thereof. A plurality of locking tabs can
extend into each of said openings adapted to retain insulators therein.
The insulators can be mounted within each of the openings. Locking tabs
can be located within each of the openings wherein the insulators are
retained within the openings by the locking tabs. The locking tabs can be
bent in at least one of a first lateral direction and a second lateral
direction whereby the locking tabs prevent movement of the insulators
within the openings in the at least the first and second directions. The
at least one transverse support can comprise at least two transverse
supports wherein the plurality of openings on one transverse support are
aligned with the plurality of openings on another transverse support. A
heater coil can be wound in serpentine fashion through the plurality of
openings in each transverse support. The at least one transverse support
member can be a single planar member.
A support flange can be formed integrally with each end of the at least one
transverse support and can extend between the end of the at least one
transverse support and the adjacent side beam. Each support flange can be
twisted so that the axis of each of the plurality of openings is parallel
to the longitudinal axes of the opposing side beams. At least one of the
openings on the at least one transverse support can comprise a circular
aperture therein. The transverse support has a first transverse edge and
at least one of the openings on the at least one transverse support
comprises a partial circular aperture extending inwardly from the
transverse edge.
In another aspect, the invention comprises a retainer bracket for an
electric heating assembly comprising a pair of parallel and opposing side
beams having longitudinal axes, at least one transverse support formed
integral with the pair of side beams and extending between the pair of
side beams wherein the transverse support has a plurality of openings with
longitudinal axes. The transverse support is preferably disposed so that
the axes of the openings are parallel to the longitudinal axes of the side
beams. A support flange is preferably formed integrally with each end of
the at least one transverse support and extends between the end of the at
least one transverse support and the adjacent side beam. Each support
flange is preferably twisted so that the axis of each of the plurality of
openings is parallel to the longitudinal axes of the opposing side beams.
In a further aspect, the invention relates to an electric heating assembly
comprising a heating element supported by a plurality of insulators
mounted to a retainer bracket. The retainer bracket comprises a pair of a
pair of parallel and opposing side beams having longitudinal axes and at
least one transverse support formed with the pair of side beams and
extending between the pair of side beams. The transverse support has a
plurality of openings with longitudinal axes wherein the transverse
support is preferably disposed so that the axes of the openings are
parallel to the longitudinal axes of the side beams. The invention
relating to an improvement in an assembly of this type wherein the
plurality of openings are each adapted to receive and retain an insulator
without a separate fastener.
In yet an additional aspect, the invention relates to an electric heating
assembly comprising a heating element supported by a plurality of
insulators mounted to a retainer bracket. The retainer bracket comprises a
pair of a pair of parallel and opposing side beams having longitudinal
axes and at least one transverse support formed with the pair of side
beams and extending between the pair of side beams. The transverse support
has a plurality of openings with longitudinal axes and wherein the
transverse support is preferably disposed so that the axes of the openings
are parallel to the longitudinal axes of the side beams. The invention
relating to an improvement in an assembly of this type wherein each of the
at least one transverse support is formed from a planar length of material
formed unitary with the side beams.
In another aspect, the invention relates to a method of forming a heating
coil retainer bracket for an electric heating assembly by advancing a
piece of sheet metal though a plurality of workstations comprising the
steps of removing excess material from the piece of sheet metal to form a
pair of parallel and opposing side beams having longitudinal axes, at
least one planar transverse support extending between the pair of side
beams, and a plurality of openings with longitudinal axes in the at least
one transverse support; bending the at least one transverse support
wherein the axes of the openings are parallel to the longitudinal axes of
the side beams; and mounting an insulator within each of the plurality of
openings.
The method can also include additional steps such as bending the side beams
into a channel beam; forming retainer tabs on the openings; forming
support flanges on the ends of the transverse support; and twisting the
support flanges during the step of bending the at least one transverse
support. The invention also contemplates a heater coil retainer bracket
formed by these steps.
In yet a further aspect, the invention relates to a method of forming an
electric heating assembly comprising the steps of removing excess material
from a piece of sheet metal to form a pair of parallel and opposing side
beams having longitudinal axes, at least one planar transverse support
extending between the pair of side beams, and a plurality of openings with
longitudinal axes in the at least one transverse support; bending the at
least one transverse support wherein the axes of the openings are parallel
to the longitudinal axes of the side beams; mounting an insulator within
each of the plurality of openings; and winding a heating coil in
serpentine fashion through longitudinal bores in the insulators. The
invention also contemplates an electric heating assembly formed by this
method.
Other objects, features, and advantages of the invention will be apparent
from the ensuing description in conjunction with the accompanying drawings
.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a perspective view of a partially-formed heating coil retainer
bracket;
FIG. 2 is a perspective view, partially broken away, of a completed
retainer bracket having a heating coil wound therethrough;
FIG. 3 is a fragmentary cross-sectional view of a ceramic insulator mounted
in an aperture of the support beam taken along line 3--3 of FIG. 2;
FIG. 4 is a fragmentary, perspective view of a second embodiment of the
heating coil retainer bracket of FIG. 1; and
FIG. 5 is a fragmentary, perspective view of a third embodiment of the
heating coil retainer bracket of FIG. 1.
DETAILED DESCRIPTION
Referring now to the drawings and to FIG. 1 in particular, a
partially-formed heating coil retainer bracket, shown generally at 10,
comprises a pair of parallel side beams 12 and 14 which support several
transversely-extending supports 16. Each transverse support 16 comprises a
support beam 18 connected to the side beams 12 and 14 by narrow support
flanges 20 and 22, respectively. The support flanges 20 and 22 include
ends 20a and 22a, which are adjacent the beam 18, and ends 20b and 22b, 5
which are adjacent the parallel side beams 12 and 14, respectively, as
shown in FIG. 2.
Each support beam 18 further includes a plurality of apertures 24 in spaced
linear relationship along a longitudinal axis of the support beam 18. The
apertures 24 include several circumferentially-spaced tabs 26 for securing
ceramic insulators 28 within the apertures 24.
As shown in FIG. 3, the ceramic insulators 28 comprise a cylindrical body
having a coaxial longitudinal bore 36 therethrough and a circumferential
ridge 34 centered thereon.
It will be understood that the retainer bracket 10 of FIG. 1 is shown
following a stamping process to form the bracket 10 and prior to a
finishing process. In the finishing process, the retainer bracket 10 is
formed into the configuration in FIGS. 2-3 and provided with the
insulators 28 and the heater coil 30.
As shown in FIGS. 2-3, the parallel side beams 12 and 14 of the retainer
bracket 10 comprise opposing L-shaped supports having a longitudinal axis
12c and 20 14c, respectively. The side beam 12 includes a substantially
vertical face 12b and a substantially horizontal face 12a, and the side
beam 14 includes a substantially vertical face 14b and a substantially
horizontal face 14a. The support flanges 20 and 22, adjacent either end of
the support beams 18, include a bend 32 formed by rotating the ends 20a
and 22a approximately 90 degrees relative to the ends 20b and 22b so that
the support beams 18 of the transverse supports 16 are disposed vertically
and the apertures 24 are axially aligned.
The insulators 28 are placed within each aperture 24 and retained therein
by bending each tab 26 forwardly and rearwardly of the ridge 34 on the
insulator 28. Thus, the tabs 26 prevent axial movement of the insulators
with respect to the corresponding aperture 24.
The heating coil 30 is passed in a serpentine fashion through the bores 36
of the insulators 28 in an aligned set of apertures 24 as shown in FIG. 2.
Ends of the heating coil 30 can be connected to a source of power in a
conventional manner whereby actuation of the power source causes the
heating coil to emit thermal radiation. The insulators 28 prevent
excessive heat from being transmitted to the retainer bracket 10 and also
provide electrical insulation between the retainer bracket 10 and the
heating coil 30.
The retainer bracket 10 is manufactured by the following steps. First,
excess material is removed from a flat blank (not shown), preferably sheet
metal, via stamping or a similar process to form the retainer bracket 10
as shown in FIG. 1, comprising the parallel side beams 12 and 14
supporting the transverse support beams 18. The removal of excess material
also forms the apertures 24, which are formed in a spaced relation and
include the tabs 26. The side beams 12 and 14 are bent upwardly along
longitudinal axes 12c and 14c, respectively, to form integral side beams
for the support of the retainer bracket 10 having opposing L-shaped cross
sections defined by horizontal portions 12a and 14a, and
upwardly-extending portions 12b and 14b, respectively, as shown in FIG. 2.
The ceramic insulators 28 are then mounted within the apertures 24 on the
support beam 16, as shown in FIG. 3, and previously described. The
transverse supports 16 are bent at the support flanges 20 and 22 to form
the bends 32, such that the rectangular beam 18 is disposed vertically and
sets of the apertures 24 are aligned axially, as shown in FIG. 2. The
heating coil 30 is wound in the conventional, serpentine fashion and
passed axially through the longitudinal bores 36 of the connectors 28,
whereby the heating coil 30 is secured in the retainer bracket 10 as shown
in FIG. 2.
FIGS. 4-5 show first and second embodiments, respectively, of the heating
coil retainer bracket 10 shown in FIG. 1. It will be understood that
common reference numerals are employed to identify common elements between
the first embodiment shown in FIGS. 1-3 and the alternative embodiments
shown in FIGS. 4 and 5.
FIG. 4 is a fragmentary, perspective view of a second embodiment of the
heating coil retainer bracket 10 shown in FIG. 1. In this embodiment, the
transverse support 16 has openings 36 which are formed as partial circular
recesses extending inwardly from an edge 38 of the transverse support 16.
The support flanges 20 and 22 are deformed to position the transverse
support in a generally vertical position as described with respect to the
previous embodiment of FIGS. 1-3. The openings 36 can be provided with
locking tabs 26 as well.
FIG. 5 is a fragmentary, perspective view of a third embodiment of the
heating coil retainer bracket of FIG. 1. In this embodiment, the
transverse support 16 has a folding axis 40 defined adjacent to and
parallel to an edge 42 thereof. The transverse support 16 is deformed
along the folding axis 40 to be located in a generally orthogonal position
relative to the side beams 12 and 14. It should be noted that, in this
embodiment, the support flanges 20 and 22 are not deformed but rather the
transverse support 16 is deformed along the folding axis 40 to position
the transverse support 16 in the orthogonal position (shown in phantom
lines in FIG. 5).
In any of the embodiments, it should be noted that the transverse support
16 is located in a position wherein longitudinal axes of the openings 36
are generally parallel to the side beams 12 and 14. Because the side beams
and transverse support 16 are formed integral with one another, the
transverse support 16 can be stamped from a single piece of material is
located in the orthogonal position by deformation of the transverse
support 16 itself, or by deforming the support flanges 20 and 22.
In any event, the resulting retainer bracket 10 is low cost and efficient
to manufacture requiring, at a minimum, stamping the retainer bracket out
of a suitable piece of material and positioning the transverse support 16
into a generally orthogonal position so that the heating coil 30 can be
wound in a serpentine fashion through the aligned openings 36.
While particular embodiments of the invention have been shown, it will be
understood, of course, that the invention is not limited thereto since
modifications may be made by those skilled in the art, particularly in
light of the foregoing teachings. Reasonable variation and modification
are possible within the scope of the foregoing disclosure of the invention
without departing from the spirit of the invention.
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